f:protected areatechnic ramemakerpm my07ipm's700 … 700 diesel t3.pdf · 2018. 12. 13. ·...

2007

700 DieselZUGMASCHINE

NOTE: The illustrations used in this Parts Manual are for reference to replacement part numbers only and are not tobe used for assembly. For assembly procedures, use an Arctic Cat Service Manual. Underlined part numbers are newfor the 2007 model year.2007 Arctic Cat AG Printed 2007®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

TABLE OF CONTENTS2007 ATV 700 Diesel Zugmaschine

Red Green

FRONT BODY PANEL ASSEMBLY ............................................................................................................................ 1REAR BODY PANEL ASSEMBLY .............................................................................................................................. 2TAILLIGHT ASSEMBLY .............................................................................................................................................. 3DECALS ...................................................................................................................................................................... 4FRAME AND RELATED PARTS ................................................................................................................................. 5SEAT ASSEMBLY ....................................................................................................................................................... 6REAR RACK AND BACKREST ASSEMBLY .............................................................................................................. 7STEERING POST ASSEMBLY ................................................................................................................................... 8HANDLEBAR ASSEMBLY .......................................................................................................................................... 9FRONT SUSPENSION ASSEMBLY ......................................................................................................................... 10REAR SUSPENSION ASSEMBLY ............................................................................................................................ 11WHEEL AND TIRE ASSEMBLY ................................................................................................................................ 12AUXILIARY BRAKE ASSEMBLY .............................................................................................................................. 13HYDRAULIC HAND BRAKE ASSEMBLY ................................................................................................................. 14HYDRAULIC BRAKE ASSEMBLY ............................................................................................................................ 15FUEL TANK ASSEMBLY .......................................................................................................................................... 16REVERSE SHIFT LEVER ASSEMBLY ..................................................................................................................... 17AIR INTAKE ASSEMBLY .......................................................................................................................................... 18BATTERY ASSEMBLY .............................................................................................................................................. 19ENGINE AND EXHAUST .......................................................................................................................................... 20COOLING ASSEMBLY .............................................................................................................................................. 21CASE/BELT COOLING ASSEMBLY ......................................................................................................................... 22DRIVE TRAIN ASSEMBLY ....................................................................................................................................... 23FRONT DRIVE GEARCASE ASSEMBLY ................................................................................................................. 24REAR DRIVE GEARCASE ASSEMBLY ................................................................................................................... 25WIRING HARNESS ASSEMBLY ............................................................................................................................... 26CLUTCHES AND DRIVE BELT ASSEMBLIES ......................................................................................................... 27TRANSMISSION RIGHT-SIDE ASSEMBLY ............................................................................................................. 28TRANSMISSION LEFT-SIDE ASSEMBLY ................................................................................................................ 29CRANKSHAFT ASSEMBLY ...................................................................................................................................... 30PISTON SET AND CONNECTING ROD ASSEMBLY .............................................................................................. 31FLYWHEEL AND RING GEAR ASSEMBLY ............................................................................................................. 32DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY ......................................................................................... 33CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES .......................................................... 34CYLINDER HEAD AND PRECOMBUSTION CHAMBER ASSEMBLY ..................................................................... 35ROCKER ARM COVER AND BREATHER SYSTEM ASSEMBLIES ........................................................................ 36FUEL SYSTEM INJECTION PUMP ASSEMBLY ...................................................................................................... 37CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC ............................................................................................... 38CAM PULLEYS, TIMING BELT, AND SPEED GOVERNOR ASSEMBLY ................................................................ 39ROCKER ARM, VALVES, AND OIL SWITCH ASSEMBLIES ................................................................................... 40EXHAUST MANIFOLD ASSEMBLY .......................................................................................................................... 41THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES ................................................ 42OIL PUMP ASSEMBLY ............................................................................................................................................. 43OIL PAN ASSEMBLY ................................................................................................................................................ 44THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES .............................................................. 45FUEL FILTER, ELECTRO-VALVE, AND HOSES ASSEMBLY ................................................................................. 46FUEL FEED PUMP AND PUSH ROD ASSEMBLIES ............................................................................................... 47WATER PUMP ASSEMBLY ...................................................................................................................................... 48INTAKE MANIFOLD AND THROTTLE CONTROL ASSEMBLY ............................................................................... 49EXTERNAL ALTERNATOR ASSEMBLY .................................................................................................................. 50STARTER MOTOR ASSEMBLY ............................................................................................................................... 51BELT GUARD ASSEMBLY ....................................................................................................................................... 52CONTROL SWITCH HOUSING ASSEMBLY ............................................................................................................ 53THROTTLE CASE ASSEMBLY ................................................................................................................................ 54TOP END GASKET SET ASSEMBLY ....................................................................................................................... 55BOTTOM END GASKET SET ASSEMBLY............................................................................................................... 56RELATED ITEMS .........................................................................................................................................Back Cover

2007 ATV 700 Diesel Zugmaschine

FRONT BODY PANEL ASSEMBLY0741-960

1 1506-883 1 Rack - Front - Assembly (inc. 2-5)2 0411-576 1 ð Decal, Warning - Front Rack Load3 2406-014 6 ð Bushing, Rack4 0441-592 4 ð Bushing, Rack5 1441-049 2 ð Plug, Rack6 8410-830 4 Screw, Machine7 0423-669 4 Spacer8 0423-465 4 Grommet9 8432-802 4 Nut, Lock

10 2506-322 1 Panel, Fender - Front (inc. 11)2506-324 1 Panel, Fender - Front (Green) (inc. 11)

11 0411-818 1 ð Decal, Reflector - Front - Right0411-819 1 ð Decal, Reflector - Front - Left

12 1406-358 1 Cover, Access13 0423-535 2 Rivet, Reinstallable14 1406-484 1 Cover, Steering Post15 0623-362 12 Rivet, Reinstallable16 0470-513 1 Cover, Storage Box17 2506-234 1 Lid, Storage Box w/Latch (inc. 18-19)18 0470-514 1 ð Lid, Storage Box 19 1406-599 1 ð Latch, Storage Box20 0123-788 AR Cable Tie - 7.5 in.21 2406-404 1 Panel, Side - Lower - Right

2406-405 1 Panel, Side - Lower - Left22 0423-101 5 Screw, Body23 0423-654 2 Screw, Shoulder

24 8050-222 2 Washer25 0423-540 2 Nut, Lock26 0509-036 1 Headlight Assembly - Right (inc. 27, 37-

42)0509-037 1 Headlight Assembly - Left (inc. 27, 37-42)

27 0409-096 2 ð Bulb, Headlight28 0623-785 4 Screw, Self-Tapping29 8050-217 8 Washer30 0423-447 4 Grommet31 0423-513 2 Knob, Adjuster32 0423-522 2 Spring, Adjuster33 0423-514 2 Stud, Adjuster - Headlight34 2506-434 1 Panel, Splash - Right

2506-383 1 Panel, Splash - Left35 0423-342 2 Screw, Self-Tapping36 AC008-011 1 Holder Panel Left 500/65037 AC008-012 1 Holder Panel Right 500/60038 0409-099 2 Bulb, Turn Signal39 0409-101 2 Bulb, Position Light40 0409-100 2 Socket, Bulb Turn41 0409-097 2 Retainer Bulb42 0409-102 2 Socket, Bulb Postion Light43 0409-098 2 Boot H/L Rubber

36

27

37

38 39

40 41 42 43

1


REAR BODY PANEL ASSEMBLY0742-246

1 2506-221 1 Rack, Rear - Assembly (inc. 2-6)2 0541-504 2 ð Pin - Assembly (inc. 3)3 0423-635 2 ð ð Pin, Roll4 0423-677 2 ð Collar5 0423-636 2 ð Spring6 0441-592 4 ð Bushing, Rack7 8410-835 4 Screw, Machine8 0423-669 4 Spacer9 0423-465 4 Grommet

10 8432-802 4 Nut, Lock11 2506-352 1 Panel, Fender - Red (inc. 12)

2506-354 1 Panel, Fender - Green (Green) (inc. 12)12 0411-820 1 ð Decal, Reflector - Right

0411-821 1 ð Decal, Reflector - Left 13 0423-654 2 Screw, Shoulder14 2506-092 1 Bracket, Rear Fender - Right

2506-093 1 Bracket, Rear Fender - Left15 0423-087 2 Washer

16 8050-222 2 Washer17 0423-540 40 Nut, Lock18 0423-101 2 Screw, Body19 0423-419 24 Screw, Machine20 2406-042 1 Footwell, Rear - Right

2406-043 1 Footwell, Rear - Left21 2506-193 1 Footwell - Right

2406-471 1 Footwell - Left22 0423-355 8 Screw, Shoulder23 1506-125 4 Footpeg24 8477-620 2 Screw, Machine

25 0423-719 2 Screw, Self-Tapping26 2406-531 1 Panel, Splash27 0405-261 1 Bushing, Splash Panel28 8050-282 1 Washer29 8409-020 1 Screw, Cap30 1411-508 1 Decal, Storage

2


TAILLIGHT ASSEMBLY0739-667

1 0509-022 1 Taillight Assembly (inc. 2-4)2 0509-025 1 ð Housing, Taillight3 0409-056 1 ð Bulb, Taillight4 0409-057 1 ð Socket, Taillight5 0623-301 2 Screw, Self-Tapping6 8053-212 2 Washer, Lock - External Tooth7 AC008-231 1 Bracket Number Plate 500/650 model

2005/068 AC008-139 2 Reflector9 AC003-063 1 Rear Light Assy Left 3/1 Zugmaschine

(inc. 15,18,24,25)10 AC003-064 1 Rear Light Assy Right 3/1 Zugmaschine

(inc. 15,18,24,25)11 AC003-015 3 Control Light Green12 AC003-148 1 Fog Light MF

13 AC008-049 1 Bracket Fog Light14 AC003-147 1 Number Plate Light MF15 AC003-097 2 Bulb 21/5 Watt16 AC003-093 1 Bulb 10 Watt17 AC003-094 1 Bulb 21 Watt18 AC003-088 2 Indicator Bulb 12V 21W (gelb)19 AC008-247 2 Hexagon Socket Screw M5x2020 AC008-424 4 Stop Nut M621 AC008-423 2 Large Diameter Washer 6x2022 AC008-248 4 Hexagon Socket Screw M6x2023 AC008-249 4 Washer 624 AC003-029 1 Indicator Rear PROWLER25 AC003-030 1 Brake and Tail Light PROWLER

7

8

11

12

14

15

16

17

9

10

18

13

1920

2123

22

24 25

3


DECALS

0741-995 *Included on Front/Rear Fender Panels

1 1441-490 1 Decal, Warning - Reverse/Pre-Ride*2 0411-894 1 Decal, Warning - Hill*3 0411-426 1 Decal, Warning - Clutch Cover4 1411-644 1 Decal, Instrument Pod

1411-646 1 Decal, Instrument Pod (Green)5 0411-966 1 Decal, Warning - Differential Lock6 0411-833 1 Decal, Passenger*7 0411-832 1 Decal, Warning - Tire Pressure*8 1411-356 1 Decal, Side - Upper Right

1411-357 1 Decal, Side - Upper Left1411-358 1 Decal, Side - Upper Right (Green)1411-359 1 Decal, Side - Upper Left (Green)

9 1411-645 2 Decal, Graphic - Lower1411-647 2 Decal, Graphic - Lower (Green)

10 1411-050 1 Decal, Speedrack11 0411-501 1 Decal, Front Bumper - “Arctic Cat”12 1411-269 1 Decal, Warning - Passenger*13 1411-251 1 Decal, Warning - Seat/Passenger*14 1411-077 1 Decal, Warning - Towing15 1411-574 1 Decal, Warning - Off-Road Only*16 0411-753 1 Decal, Warning - Age/General

4


FRAME AND RELATED PARTS0741-977

1 2506-006 1 Frame, Main2 8408-816 11 Screw, Cap3 1506-548 1 Channel, Shock Support4 8409-020 4 Screw, Cap5 2506-283 1 Channel, Bumper Mounting - Right

2506-285 1 Channel, Bumper Mounting - Left6 1506-562 1 Bracket, Mounting - Bumper - Right

1506-563 1 Bracket, Mounting - Bumper - Left7 1506-855 1 Bumper8 8468-845 2 Screw, Machine9 1506-667 2 Strap, Bumper Support

10 8424-805 2 Nut, Lock11 8428-002 2 Nut, Lock12 1506-429 1 Brace, A-Arm13 8409-025 2 Screw, Cap14 2406-253 1 Panel, Belly15 0423-101 17 Screw, Body16 0406-289 2 Pad, Frame17 8424-802 4 Nut, Flange18 8409-016 3 Screw, Cap19 2406-216 1 Strap, Footrest - Right

2406-217 1 Strap, Footrest - Left20 1506-848 1 Footrest - Right

1506-849 1 Footrest - Left21 AC008-064 1 Towing Device 400/500/60022 AC008-050 1 Pipe Clamp 30/1523 1406-360 1 Facia, Bumper - Front (Black)24 AC003-158 1 Horn

2406-321 1 Bracket Mount Horn25 AC008-751 1 Mirror Left26 AC008-752 1 Mirror Right27 AC008-753 1 Mirror Mounting Left28 AC008-403 1 Mirror Adapter 2007 Right29 AC008-244 3 Lens Head Screw M5x3530 AC008-227 3 Stop Nut M531 AC008-246 3 Large Diameter Washer 5x1532 AC008-423 1 Large Diameter Washer 6x2033 AC008-248 1 Hexagon Socket Screw M6x2034 AC008-250 1 Tooth Lock Washer 35 0423-419 2 Screw, Mach-TSTRH-M6-1.0 X 16 Black36 0423-101 2 Screw, Body - 6 mm

21 7

22 23

24

25

26

28

27

29

30

31

32

33

34

35

36

5


SEAT ASSEMBLY0739-690

1 1506-937 1 Seat Assembly (inc. 2-9)2 1506-209 1 ð Cover, Seat3 1506-208 1 ð Foam, Seat4 2406-144 1 ð Base, Seat - Assembly (inc. 5-6)5 0406-879 2 ð ð Bumper, Seat - Rear

6 0406-877 4 ð ð Bumper, Seat - Front7 0624-528 AR ð Staple8 1406-592 1 ð Spring, Seat Latch9 1506-156 1 ð Latch, Seat

6


REAR RACK AND BACKREST ASSEMBLY0742-248 *Not Illustrated

1 0541-438 1 Rack, Rear - Assembly (inc. 2-7)2 1441-049 2 ð Plug3 2406-014 8 ð Bushing4 0441-592 4 ð Bushing5 0411-814 1 ð Decal, “Arctic Cat”6 0411-648 1 ð Decal, Warning - Rear Rack Load7 0411-965 2 ð Decal, Speedrack

8 0541-486 1 Bracket, Backrest9 8408-816 4 Screw, Cap

10 0506-686 1 Backrest11 8476-620 4 Screw, Machine12 0541-447 2 Pin

* 0453-349 1 Instructions

7


STEERING POST ASSEMBLY0739-774

1 8408-860 4 Screw, Cap2 0405-035 4 Cap, Steering Adjuster3 0423-505 2 Screw, Shoulder4 0405-166 1 Cap, Housing5 0405-138 1 Housing, Lower6 0405-139 1 Housing, Upper7 0505-451 1 Post, Steering8 8408-816 2 Screw, Cap9 0602-233 1 Flange, Bearing

10 0405-052 1 Bearing w/Inverted Oil Seal

11 0423-073 1 Washer12 8409-020 1 Screw, Cap13 0505-408 2 Tie Rod - Assembly (inc. 14-18)14 0405-083 2 ð Ball Joint, Tie Rod - Left-Hand Thread15 0423-013 2 ð Nut - Left-Hand Thread16 0405-107 2 ð Tie Rod17 8420-002 2 ð Nut - Right-Hand Thread18 0405-082 2 ð Ball Joint, Tie Rod - Right-Hand Thread19 0423-157 4 Nut, Top Lock20 0623-175 4 Pin, Cotter

8


HANDLEBAR ASSEMBLY0742-256

1 0505-476 1 Tube, Handlebar2 0405-218 2 Plug, Handlebar3 0405-149 2 End Cap, Handlebar4 8050-247 2 Washer5 8477-845 2 Screw, Machine6 0405-147 2 Grip, Handlebar7 0409-013 1 Cover, Key8 0430-036 1 Switch, Ignition - Assembly (inc. 9)9 3409-007 1 ð Key, Ignition - Blank (C Series)

3409-011 1 ð Key, Ignition - Blank (D Series)3409-012 1 ð Key, Ignition - Blank (E Series)3409-013 1 ð Key, Ignition - Blank (F Series)

10 1506-578 1 Bracket, Mounting - Instrument Pod

11 0505-495 1 Instrument Pod0505-496 1 Instrument Pod (Green)

12 0423-535 2 Rivet, Reinstallable13 0520-024 1 Gauge, LCD14 0420-065 1 Clamp, Plastic15 0423-493 2 Nut w/Washer16 0502-527 1 Control, Differential Lock (inc. 17)17 0502-613 1 ð Clamp, Differential Lock Control - Kit18 0487-050 1 Cable, Differential Lock19 0641-897 1 Outlet, Accessory - 12V20 0420-074 1 Light, Indicator - Glow Plug21 0420-075 1 Light, Indicator - Battery

9


FRONT SUSPENSION ASSEMBLY0742-247

1 0403-137 2 Shock Absorber - Front (inc. 2-3)2 0604-310 8 ð Bushing, Shock Absorber3 0403-028 4 ð Sleeve, Shock4 0403-102 2 Cam, Spring Adjuster5 0503-318 2 Spring, Shock Absorber - Platinum

0503-317 2 Spring, Shock Absorber - Black (Green)6 1603-889 2 Retainer, Spring7 8409-040 4 Screw, Cap8 8428-002 10 Nut, Lock9 0503-272 1 A-Arm, Upper Right - Platinum (inc. 10-13)

0503-273 1 A-Arm, Upper Left - Platinum (inc. 10-13)0503-196 1 A-Arm, Upper Right - Black (inc. 10-13)

(Green)0503-197 1 A-Arm, Upper Left - Black (inc. 10-13)

(Green)10 0403-081 4 ð Bushing11 0403-080 2 ð Collar12 0423-009 4 ð Clip, Ball Joint13 0405-115 4 ð Ball Joint - Front14 0503-342 1 A-Arm, Lower Right - Platinum

(inc. 12-13 and 15-16)0503-343 1 A-Arm, Lower Left - Platinum

(inc. 12-13 and 15-16)0503-334 1 A-Arm, Lower Right - Black

(inc. 12-13 and 15-16) (Green)0503-335 1 A-Arm, Lower Left - Black

(inc. 12-13 and 15-16) (Green)

15 0403-115 8 ð Bushing16 0403-114 4 ð Collar17 0505-460 1 Knuckle - Assembly - Right (inc. 18-19)

0505-461 1 Knuckle - Assembly - Left (inc. 18-19)18 1402-027 2 ð Bearing, Wheel Hub19 0423-423 2 ð Ring, Retaining20 8409-030 4 Screw, Cap21 0423-334 2 Screw, Cap22 8409-075 4 Screw, Cap23 0502-813 1 Axle, Drive - Front - Left (inc. 24-25)

0502-812 1 Axle, Drive - Front - Right (inc. 24-25)24 1441-109 2 ð Clip, Retaining25 0436-276 2 ð Repair Kit, Boot26 0441-752 1 Guard, Boot - Right - Red

0441-753 1 Guard, Boot - Left - Red1441-002 1 Guard, Boot - Right - Green (Green)1441-003 1 Guard, Boot - Left - Green (Green)

27 0423-545 4 Screw, Body28 0441-587 1 Wrench, Spanner

10


REAR SUSPENSION ASSEMBLY0741-439

1 0504-372 1 Knuckle, Right Rear - Assembly (inc. 2-5)0504-373 1 Knuckle, Left Rear - Assembly (inc. 2-5)

2 1402-027 2 ð Bearing, Wheel Hub3 0423-423 2 ð Ring, Retaining4 0403-038 4 ð Collar, Suspension Bushing5 0403-032 8 ð Bushing, Suspension6 0504-440 1 A-Arm, Rear - Lower Right - Platinum

(inc. 7-8)0504-441 1 A-Arm, Rear - Lower Left - Platinum

(inc. 7-8)0504-438 1 A-Arm, Rear - Lower Right - Black

(inc. 7-8) (Green)0504-439 1 A-Arm, Rear - Lower Left - Black (inc. 7-8)

(Green)7 0403-115 16 ð Bushing8 0403-114 8 ð Collar9 8428-002 14 Nut, Lock

10 8409-000 4 Screw, Cap11 0504-476 1 A-Arm, Rear - Upper Right - Platinum

(inc. 7-8)0504-477 1 A-Arm, Rear - Upper Left - Platinum

(inc. 7-8)0504-470 1 A-Arm, Rear - Upper Right - Black (inc. 7-8)

(Green)0504-471 1 A-Arm, Rear - Upper Left - Black (inc. 7-8)

(Green)

12 0441-754 1 Guard, Boot - Right - Red0441-755 1 Guard, Boot - Left - Red1441-004 1 Guard, Boot - Right - Green (Green)1441-005 1 Guard, Boot - Left - Green (Green)

13 0423-545 4 Screw, Body14 8409-075 8 Screw, Cap15 0502-811 2 Axle, Drive - Rear (inc. 16-17)16 0441-893 2 ð Clip, Retaining17 0436-276 2 ð Repair Kit, Boot18 0441-587 1 Wrench, Spanner19 1603-889 2 Retainer, Spring20 0404-145 2 Spring, Suspension - Platinum

0404-144 2 Spring, Suspension - Black (Green)21 0404-057 2 Cam, Spring Adjuster22 0404-147 2 Shock Absorber - Rear (inc. 23-25)23 0403-182 2 ð Bushing, Double-Bonded24 0603-955 4 ð Bushing, Shock Absorber25 1603-219 2 ð Sleeve, Shock Absorber26 0423-087 2 Washer27 8408-820 2 Screw, Cap28 8409-050 2 Screw, Cap29 0123-788 2 Cable Tie

11


WHEEL AND TIRE ASSEMBLY0741-559

1 0423-557 12 Screw, Shoulder w/Loctite2 1402-225 3 Disc, Brake3 0502-599 2 Hub, Wheel - Front (inc. 4)4 0402-974 16 ð Stud, Wheel Hub5 0502-601 1 Hub, Wheel - Rear - Left (inc. 4)

0502-599 1 Hub, Wheel - Rear - Right (inc. 4)6 0423-607 4 Nut, Castle 7 0423-407 4 Pin, Cotter8 1402-127 2 Wheel - Front - Platinum

1402-115 2 Wheel - Rear - Platinum0402-856 2 Wheel - Front - Gray (Green)0402-858 2 Wheel - Rear - Gray (Green)

9 0423-408 16 Nut, Mounting - Wheel10 1402-548 2 Tire - Front

1402-549 2 Tire - Rear11 0402-064 4 Stem, Valve (inc. 12)

12 0402-140 4 ð Cap, Valve Stem13 0502-464 1 Wheel, Assembly - RH 25x8-12 (Gray)14 0502-465 1 Wheel, Assembly - LH 25x8-12 (Gray)15 0502-505 1 Wheel, Assembly - RH 25x11-12 (Gray)16 0502-506 1 Wheel, Assembly - LH 25x11-12 (Gray)17 AC007-203 2 Wheel Assy. Onroad Front

(inc. 20, 22, 23)18 AC007-216 2 Wheel Assy. Onroad Rear

(inc. 21-23) 19 AC007-217 16 Nut, Aluminium Rim Silver20 AC007-202 1 Road Tire 185/65-1521 AC007-215 1 Road Tire 205/60-1522 AC007-209 1 Valve Wheel, Road Tire23 AC007-221 1 Aluminium Rim Silver

13/14

15/16

17/18

19

20/21

22

23

12


AUXILIARY BRAKE ASSEMBLY0741-314R *Not a Service Part

1 1502-063 1 Lever, Brake2 1602-213 2 O-Ring3 8050-252 1 Washer4 8408-816 1 Screw, Cap5 0502-807 1 Spring, Brake Lever6 1502-153 1 Brake Assembly (inc. 7-9)7 * 1 ð Master Cylinder8 1502-154 1 ð Hose, Brake Reservoir w/clamps9 1502-155 1 ð Reservoir, Brake

10 0623-038 1 Nut, Flanged11 8476-616 1 Screw, Machine12 0123-788 1 Cable Tie - 7.5 in.13 1502-140 1 Hose, Brake14 0423-178 6 Washer, Crush15 0423-413 3 Bolt, Banjo-Fitting16 1502-179 1 Bracket, Switch17 8408-625 2 Screw, Cap18 0502-785 1 Spring, Brake Switch19 1623-589 2 Screw, Cap20 0502-878 1 Caliper, Brake (inc. 21-27) 21 0502-603 1 ð Housing, Caliper - Assembly - Right Rear

(inc. 22-24)

22 0502-606 1 ð ð Piston/Seal Set (inc. 23)23 0502-607 1 ð ð ð Seal Set24 0502-609 1 ð ð Valve, Bleed25 0502-608 1 ð O-Ring, Guide - Set26 0502-605 1 ð Bracket Assembly27 0502-875 1 ð Pad, Brake - Set28 1502-115 2 Clip, Brake Hose29 1502-138 1 Adapter, Hose30 AC002-006 1 Brake Calliper31 AC002-021 1 Brake Shoe For Brake Calliper32 AC002-022 1 Brake Disc 200 mm D / 4 mm 33 AC002-023 1 Spacer Brake Disc34 AC002-024 1 Bowden Cable ZUGMASCHINE 700/65035 1502-150 1 Lever, Park Brake-ACE36 AC008-236 4 Internal Hexagon Socket Screw M8x3537 AC008-237 4 Fin Screw M8x2538 AC008-238 2 Nut M1039 AC008-239 2 Internal Hexagon Socket Screw M10x8040 AC008-240 10 Washer 1041 AC008-241 2 Hexagon Socket Screw M10x4042 AC008-242 2 Stop Nut M1043 AC002-015 1 Brake Pad ZUGMASCHINE

30

34

32

33

37

38

39

40 4142

35

31

43

36

13


HYDRAULIC HAND BRAKE ASSEMBLY0741-458

1 0502-912 1 Brake Assembly (inc. 2-10)2 0502-566 1 ð Screw, Reservoir Cover - Kit3 0502-868 1 ð Cover, Reservoir - Kit4 0502-568 1 ð Screw, Master Cylinder Clamp - Kit5 0502-869 1 ð Clamp, Master Cylinder - Kit6 0502-704 1 ð Master Cylinder Assembly - Kit

7 0502-866 1 ð Lever Assembly - Kit (inc. 8-9)8 0502-867 1 ð ð Lock, Brake Lever - Kit9 0502-580 1 ð ð Lever Pin - Kit

10 0502-564 1 ð Switch, Brake - Kit11 0423-178 2 Washer, Crush12 0423-413 1 Bolt, Banjo-Fitting

14


HYDRAULIC BRAKE ASSEMBLY0741-431

1 1502-015 1 Hose, Brake - Assembly2 8476-625 1 Screw, Cap3 1623-589 4 Screw, Cap4 0502-878 1 Caliper, Brake - Right Front (inc. 5-11)

0502-879 1 Caliper, Brake - Left Front (inc. 5-11)5 0502-603 1 ð Housing, Caliper - Assembly - Right Front

(inc. 6-8)0502-611 1 ð Housing, Caliper - Assembly - Left Front

(inc. 6-8)

6 0502-606 2 ð ð Piston/Seal Set (inc. 7)7 0502-607 2 ð ð ð Seal Set8 0502-609 2 ð ð Valve, Bleed9 0502-608 2 ð O-Ring, Guide - Set

10 0502-605 2 ð Bracket Assembly11 0502-875 2 ð Pad, Brake - Set12 0423-178 2 Washer, Crush13 0423-413 1 Bolt, Banjo-Fitting

15


FUEL TANK ASSEMBLY0742-241

1 0570-143 1 Tank, Fuel - Assembly w/Straps (inc. 2-11)2 0470-653 1 ð Cap, Fuel Tank3 0570-155 1 ð Sensor, Fuel Level (inc. 4)4 0470-521 1 ð ð Seal, Fuel Level Sensor5 0470-639 1 ð Plate, Mounting - Fuel Level Sensor6 1623-158 4 ð Screw, Plastite7 0570-168 1 ð Strap, Mounting - Fuel Tank - Front8 0570-169 1 ð Strap, Mounting - Fuel Tank - Rear9 8476-650 1 ð Screw, Machine

10 8427-602 2 ð Nut, Lock11 8476-640 1 ð Screw, Machine12 0423-609 2 Screw, Mounting - Fuel Tank

13 0470-536 2 Clip, Mounting - Fuel Tank14 0423-688 2 Clamp, Hose15 0410-070 AR Hose, Fuel - 25 ft16 0423-670 5 Clamp, Hose17 0109-332 1 Fitting, T18 0423-689 2 Clamp, Hose19 0470-479 1 Shield, Fuel Tank20 0470-474 1 Shield, Heat21 0623-797 5 Screw, Self-Tapping22 0410-143 AR Hose, Fuel - 25 ft23 0410-142 AR Hose, Fuel - 25 ft

16


REVERSE SHIFT LEVER ASSEMBLY0742-244

1 0402-843 1 Knob, Reverse Shift Lever2 0423-345 1 Clip, Push3 1402-576 1 Plate, Shift4 0423-357 4 Nut, Stamped5 0502-659 1 Lever, Reverse Shift6 0502-410 1 Spring, Reverse Shift Lever7 1502-012 1 Axle, Reverse Shift Lever8 8424-602 1 Nut9 0423-182 2 O-Ring

10 0402-675 1 Axle, Pivot

11 0423-299 2 O-Ring12 8408-812 1 Screw, Cap13 0423-087 1 Washer14 0623-294 2 Nut15 1402-270 1 End, Rod16 1502-014 1 Linkage, Shift17 0423-091 1 Bushing, Shift Linkage18 0623-094 1 Washer19 0423-169 1 E-Ring

17


AIR INTAKE ASSEMBLY0741-964

1 0413-091 1 Diverter, Air - Top2 0413-093 1 Diverter, Air - Bottom3 2406-509 1 Shroud, Splash4 0623-362 2 Rivet, Reinstallable5 0423-317 2 Clamp, Boot6 0470-618 1 Duct, Air Intake7 0423-066 2 Clamp, Boot8 0470-621 1 Duct, Engine Intake9 0470-617 1 Filter, Air - Assembly (inc. 10-13)

10 0470-627 1 ð Cap, Air Filter11 0470-619 1 ð Element, Air Filter - Main12 0470-620 1 ð Element, Air Filter - Safety13 0470-628 1 ð Bracket, Mounting - Air Filter Element14 8476-620 2 Screw, Bracket15 8050-222 2 Washer16 2506-082 1 Bracket, Mounting - Air Filter17 8476-616 4 Screw, Machine

18


BATTERY ASSEMBLY0742-250 *Not Illustrated

1 5990-839 1 Battery Cover/Tool Tray Assembly (inc. 2-3)2 2406-511 1 ð Cover, Battery3 0406-288 2 ð Pad, Battery* 0444-122 1 ð Kit, Tool4 8476-620 2 Screw, Machine5 0623-325 1 Nut, Wing

6 8050-217 1 Washer7 0645-243 1 Strap, Battery - Top8 0406-289 1 Pad, Battery9 0645-311 1 Strap, Battery - Side

10 0645-432 1 Battery

19


ENGINE AND EXHAUST0741-986

1 0462-044 1 Engine2 2406-323 3 Mount, Engine - Rubber3 8468-820 2 Screw, Cap 4 8422-002 3 Nut, Lock5 2506-186 1 Mounting, Bracket - Engine6 8408-816 5 Screw, Cap7 0423-736 1 Screw, Cap8 0423-687 2 Nut9 3206-291 1 Gasket, Exhaust Manifold

10 0512-322 1 Pipe, Exhaust - Assembly (inc. 11-14)11 0412-386 1 ð Shield, Exhaust Pipe - Lower12 0412-385 1 ð Shield, Exhaust Pipe - Upper13 0512-321 1 ð Pipe, Exhaust14 0423-317 4 ð Hose Clamp15 0612-668 2 Spring16 0412-375 1 Seal, Exhaust17 1506-732 1 Channel, Muffler Support (inc. one No. 18)18 0412-215 3 ð Bushing

19 0512-306 1 Muffler (inc. 20-22)20 0412-313 1 ð Gasket, Spark Arrester21 0512-219 1 ð Arrester, Spark22 8408-616 3 ð Screw, Cap23 0412-373 1 Cover, Muffler24 8477-610 3 Screw, Machine25 0502-993 1 Gearcase - Assembly26 2506-190 1 Bracket, Mounting - Engine - Right

2506-191 1 Bracket, Mounting - Engine - Left27 8408-820 8 Screw, Cap28 2506-061 4 Washer, Engine Mount29 8408-055 3 Screw, Cap30 0408-015 1 Plate, Mounting - Engine/Transmission31 8409-030 2 Screw, Cap32 0423-685 2 Screw, Cap33 2506-189 1 Bracket, Mounting - Engine - Front34 2406-322 1 Mount, Engine - Rubber35 0423-737 1 Nut

20


COOLING ASSEMBLY0741-966

1 0413-142 1 Radiator Assembly (inc. 2-10)2 0413-156 1 ð Radiator3 0413-154 1 ð Screen, Radiator4 0423-030 2 ð Grommet5 0413-155 1 ð Shroud, Fan6 0413-123 1 ð Fan, Cooling7 8475-512 12 ð Screw, Machine8 0123-397 1 ð Clamp, Cable9 0413-045 1 ð Sensor, Temperature - Coolant

10 0423-390 1 ð O-Ring11 0610-016 AR Hose - 25 ft12 0413-002 1 Cap, Radiator13 0413-140 1 Tank, Coolant Fill14 0423-484 2 Screw, Shoulder

15 0623-038 2 Nut w/Washer16 0423-028 2 Bushing, Stem17 0423-496 3 Clamp, Hose18 0410-106 1 Hose, Coolant 19 0410-107 1 Hose, Coolant 20 1623-093 3 Clamp21 0410-121 1 Hose, Coolant - Coupler22 0124-045 1 Clamp, Hose23 0413-086 1 Tank, Coolant Overflow24 0413-087 1 Stopper, Coolant Tank25 0610-011 AR Hose, Clear - 25 ft26 0623-316 1 Cable Tie27 0123-788 2 Cable Tie

21


CASE/BELT COOLING ASSEMBLY0741-991

1 0413-132 1 Duct, Belt Cooling - Front2 0423-551 1 Clamp, Plastic3 0423-342 3 Screw, Self-Tapping4 0413-141 1 Fan, Belt Cooling5 8475-512 2 Screw, Machine6 8424-502 2 Nut, Hex7 0423-018 1 Clamp, Boot8 0413-133 1 Boot, Belt Cooling - Inlet9 0423-550 2 Clamp, Plastic

10 1502-157 1 Cover, Clutch11 0830-013 1 Washer, Crush12 8408-812 1 Screw, Cap13 1402-528 1 Gasket, V-Belt Cover14 0829-002 2 Dowel, Split

15 8473-820 4 Screw, Machine16 8468-630 16 Screw, Machine17 0423-118 5 Screw, Self-Tapping18 1402-527 1 Cover, Clutch19 1402-525 1 Gasket, Starter20 8409-025 2 Screw, Cap21 1402-526 1 Gasket, Gearcase22 1402-524 1 Gasket, Clutch Cover23 0413-134 1 Boot, Belt Cooling - Outlet24 0423-380 1 Clamp, Boot25 0470-442 1 Valve, Drain26 0623-301 1 Screw, Self-Tapping27 0413-106 1 Duct, Belt Cooling - Rear28 0623-316 1 Cable Tie

22


DRIVE TRAIN ASSEMBLY0742-251

1 0402-147 2 Bladder, Gearcase2 0423-315 4 Clamp, Fitting3 8428-002 4 Nut, Lock4 0423-426 10 Washer5 0423-404 4 Screw, Cap6 0502-975 1 Gearcase, Front7 0402-966 1 Boot, Shaft8 0502-500 1 Plate, Cable9 0423-396 2 Screw, Self-Tapping

10 1502-079 1 Gearcase, Rear11 0410-048 AR Hose, Vent12 0123-788 1 Cable Tie

13 0470-462 1 Fitting, Vent14 0423-393 2 Clamp, Boot15 0402-985 2 Boot16 0423-411 2 Clamp, Boot17 0673-618 2 Bumper, Propeller Shaft18 1402-507 1 Shaft, Propeller19 8408-820 4 Screw, Cap20 0402-950 1 Flange, Output21 1402-026 1 Spring22 0502-976 1 Shaft, Propeller23 8409-025 3 Screw, Cap

23


FRONT DRIVE GEARCASE ASSEMBLY(Complete Assembly p/n 0502-975)

0742-249

1 1402-369 1 Yoke, Flange2 1402-164 1 Joint, Universal - Set (inc. 3)3 0423-450 4 ð Retainer4 0502-517 1 Yoke, Front End - Assembly5 1402-011 1 Seal6 0423-423 1 Ring, Retaining7 0502-579 1 Actuator (inc. one No. 8)8 0423-498 2 ð O-Ring9 0423-396 3 Screw, Self-Tapping

10 0502-347 1 Bracket, Actuator11 1402-043 1 Bearing12 0423-118 11 Screw, Self-Tapping13 0502-528 1 Housing, Pinion14 0402-947 1 Gasket, Flange15 0423-417 1 Ring, Retaining16 0402-997 1 Shaft, Selector17 0402-998 1 Fork, Selector18 0402-417 1 Shaft, Shuttle19 0423-402 1 Ring, Retaining20 0423-147 1 O-Ring21 0402-999 1 Spring, Return22 0402-413 1 Coupler, Drive23 0402-357 1 Collar, Lock24 0502-783 1 Gear, Pinion - Assembly - 10T (inc. 25-26)25 0402-336 1 ð Collar, Retaining26 0402-327 1 ð Bearing27 0402-328 1 Bearing28 0502-514 1 Housing, Gearcase29 0402-411 1 Pin, Dowel30 1402-441 2 Seal31 1402-210 1 Plug, Magnetic (inc. one No. 32)32 0423-153 2 ð O-Ring33 0423-149 1 O-Ring

34 0402-393 1 Bearing35 0402-405 AR Shim

0402-406 AR Shim0402-407 AR Shim0402-408 AR Shim0402-409 AR Shim

36 0502-851 1 Gear, Ring - 36T37 1402-074 AR Shim


38 1502-097 1 Cover, Gearcase (inc. one No. 30, one No. 32, and 39-54)

39 1402-053 1 ð Bearing40 0502-413 1 ð Flange, Bearing41 1402-079 1 ð Pin, Parallel42 1402-042 1 ð Collar, Sliding43 1402-054 1 ð Fork44 1402-058 2 ð Ring, Retaining45 1402-057 1 ð Spring46 1402-104 1 ð Fitting47 0402-419 1 ð Switch, Indicator48 1402-063 1 ð Spring49 1402-055 1 ð Shaft, Lock50 1402-056 1 ð Seal51 0423-133 1 ð O-Ring52 0423-132 1 ð Washer53 0423-424 1 ð Ring, Retaining54 1402-211 1 ð Plug, Oil Level (inc. one No. 32)55 0402-333 1 Plug, Fill (inc. 56)56 0423-154 1 ð O-Ring

24


REAR DRIVE GEARCASE ASSEMBLY(Complete Assembly p/n 1502-079)

0741-524

1 0502-622 1 Housing, Gearcase2 0402-393 2 Bearing3 1402-441 2 Seal4 1402-032 1 Gear, Ring - 36T5 0402-405 AR Shim


6 0402-326 1 Button, Thrust7 0402-429 AR Shim


8 0423-149 1 O-Ring9 1502-082 1 Cover, Gearcase

10 0402-333 1 Plug, Fill (inc. 11)11 0423-154 1 ð O-Ring12 1402-102 1 Fitting

13 0423-118 11 Screw, Self-Tapping14 0402-450 1 Plug, Magnetic (inc. one No. 15)15 0423-153 2 ð O-Ring16 0402-328 1 Bearing17 0502-783 1 Gear, Pinion - Assembly - 10T (inc. 18-19)18 0402-327 1 ð Bearing19 0402-336 1 ð Collar, Retaining20 0402-411 1 Pin, Dowel21 0402-331 1 Collar, Lock22 0402-982 1 Washer, Wave23 0402-981 1 Collar, Shaft24 0402-947 1 Gasket, Flange25 0502-529 1 Housing, Pinion26 0423-417 1 Ring, Retaining27 1402-043 1 Bearing28 0423-423 1 Ring, Retaining29 1402-011 1 Seal30 1502-085 1 Shaft, Input31 1402-211 1 Plug, Oil Level (inc. one No. 15)

25


WIRING HARNESS ASSEMBLY0742-242

1 0486-197 1 Harness, Main (inc. 2-7)2 0486-164 1 ð Tether, Accessory Connector3 0530-008 1 ð Cover, Fuse Block4 0430-037 1 ð Holder, Fuse5 0430-033 1 ð Relay - 10 Amp

0430-045 3 ð Relay - 20 Amp6 0430-032 4 ð Fuse - 10 Amp

0430-031 4 ð Fuse - 15 Amp0430-030 2 ð Fuse - 30 Amp

7 1411-381 1 ð Decal, Fuse Block8 0123-788 AR Cable Tie - 7.5 in.9 0409-072 1 Switch, Brake - Assembly

10 0445-060 1 Cable, Battery/Ground11 0445-058 1 Solenoid12 8476-625 2 Screw, Machine13 0623-038 8 Nut w/Washer14 0645-327 1 Boot, Terminal15 0445-059 1 Cable, Battery - Assembly16 0645-019 2 Boot, Terminal17 2406-388 1 Tray, Electrical18 8476-620 2 Screw, Machine19 0623-362 4 Rivet, Reinstallable

20 0423-371 1 Screw, Machine21 8424-502 1 Nut, Hex22 3206-311 1 Relay, Glow Plug23 3206-307 1 Wire, Glow Plug24 3206-306 2 Plug, Glow25 3206-308 2 Nut26 3206-309 2 Washer27 0430-049 1 Flasher, Turn Signal28 AC003-271 1 Trailer Harness - ZUG29 AC003-049 1 Harness, Rear30 AC003-223 1 Harness 200631 AC003-050 2 Harness, Headlight32 AC003-057 1 Kabelbaum - Blinker Links inc.

AC003-059 1 Kabelbaum - Blinker Rechts33 AC003-048 2 Fuse Carrier ’’MINI’’34 AC003-054 2 Connector Case Rear Indicator35 AC003-052 2 Connector Case Tail - and Brakelight36 AC003-060 2 Fuse 7,5 A

2728

36

3534

33 32

31

30

29

26


CLUTCHES AND DRIVE BELT ASSEMBLIES0742-008

1 1502-073 1 Pulley, Driven - Assembly (inc 2-10)2 1502-208 1 ð Face, Driven - Movable (inc. 3-4)3 0423-752 3 ð ð Screw, Cam4 1402-632 3 ð ð Cam, Shoe5 0423-751 1 ð Ring, Retaining6 1402-630 1 ð Cam7 0423-750 1 ð Spring8 0423-749 1 ð Shim9 1402-631 1 ð Key

10 1402-629 1 ð Face, Driven - Fixed11 0828-020 1 Washer12 0827-013 1 Nut, Driven Pulley13 1402-564 1 Belt, Drive14 1502-072 1 Pulley, Drive - Assembly (inc. 15-26)

15 0423-747 1 ð Nut, Hex16 0423-746 1 ð Washer, Lock17 1502-207 1 ð Plate, Movable Drive Face18 1402-628 3 ð Damper, Movable Drive Face19 1402-625 1 ð Face, Drive - Movable20 1502-205 6 ð Block, Weight - Assembly (inc. 21-22)21 1402-627 6 ð ð Weight22 1402-626 6 ð ð Block, Weight23 0423-745 1 ð Spring24 1402-624 1 ð Stopper25 1402-623 1 ð Seat, Spring26 1502-206 1 ð Face, Drive - Fixed27 0423-733 1 Washer28 0423-673 1 Bolt, Hex

27


TRANSMISSION RIGHT-SIDE ASSEMBLY0741-915

1 1502-043 1 Housing, Gearcase - Set2 8408-830 3 Screw, Cap3 0801-006 1 Housing, Secondary Output Shaft Bearing4 0829-002 2 Dowel, Split5 0832-014 1 Bearing, Secondary Output Shaft6 0828-016 2 Washer, Thrust7 0822-015 1 Shaft, Reverse Idle8 0822-012 1 Bushing, Reverse Idle Gear9 0822-011 1 Gear, Reverse Idle

10 0829-003 2 Dowel, Split11 0822-067 1 Shaft, Output - Secondary12 0832-015 1 Bearing, Output - Secondary Shaft13 0402-347 1 Ring, Retaining14 1402-559 1 Gear, Driven - No. 2 (42 Tooth)15 0828-063 1 Shim, 24 x 48 x 1.0516 0819-001 1 Gear, Secondary Drive17 0828-019 1 Washer, Thrust18 0827-012 1 Nut, Hex19 0832-013 1 Bearing20 1402-553 1 Shaft, Input21 0832-012 1 Bearing, Driveshaft

22 0830-035 1 Seal, Driveshaft 23 8470-520 2 Screw, Machine24 0818-049 1 Sensor, Gear Shift Position25 0423-714 1 O-Ring26 8405-640 7 Screw, Cap27 8405-855 4 Screw, Cap28 0828-040 1 Washer, Steel29 0818-046 1 Shaft, Gear Shift - Assembly (inc. 30-37)30 0831-011 4 ð Ring, Retaining31 0828-039 2 ð Washer32 0818-012 2 ð Spring, Cam - Gear Shift33 0818-027 1 ð Cam, Reverse - Gear Shift34 0818-011 1 ð C-Ring35 0818-009 1 ð Cam, Forward - Gear Shift36 0818-010 1 ð Shaft, Gear Shift37 0829-011 1 ð Pin, Dowel38 0818-017 2 Spring, Gear Shift Contacts39 0818-013 2 Contact, Gear Shift40 0828-067 2 Washer, Thrust Bearing41 0832-034 1 Bearing, Thrust - Roller42 0828-037 1 Washer

28


TRANSMISSION LEFT-SIDE ASSEMBLY0741-914

1 0832-014 2 Bearing2 0828-010 1 Washer, Thrust - Secondary Transmission3 1402-558 1 Gear, Drive - No. 2 (18 Tooth)4 1502-149 1 Countershaft (inc. 5-18)5 0831-011 4 ð Ring, Retaining6 0822-014 1 ð Dog, Reverse Gear7 0822-045 1 ð Insert, Gear8 0828-008 2 ð Washer, Secondary Transmission9 0822-013 1 ð Gear, Reverse Driven

10 0832-011 3 ð Bearing11 0822-005 3 ð Bushing12 0828-015 1 ð Washer, Lock - Secondary Transmission13 0828-014 1 ð Washer, Secondary Transmission14 0822-004 1 ð Gear, Driven - Low (40 Tooth)15 0822-046 2 ð Shim, Drive Gear Spacer16 0822-003 1 ð Countershaft17 0822-007 1 ð Dog, Sliding Driven Gear - High/Low18 0822-006 1 ð Gear, Driven - High (30 Tooth)19 0828-011 1 Washer20 0818-072 2 Fork, Shift21 0818-006 1 Shaft, Shift Fork22 0822-052 1 Seal, Countershaft - Right23 0831-040 1 Ring, External Retaining24 0822-050 1 Trigger, Speedometer Sensor25 0828-069 1 Washer, Thrust26 0831-039 1 Ring, External Retaining27 0830-129 1 Gasket, Odometer Drive28 0829-023 2 Pin, Solid Dowel29 0822-049 1 Housing, Speedometer Sensor30 0830-107 2 Seal, Fastener31 8468-645 2 Screw, Machine32 0824-015 1 Sensor, Speedometer33 8468-620 1 Screw, Machine34 0828-038 1 Washer35 0818-002 1 Stopper, Swing Arm - Cam Assembly36 0818-004 1 Support, Cam Stopper37 0818-028 1 Spring, Torsion - Cam Arm38 0828-035 1 Washer

39 8424-602 1 Nut, Hex Flange40 1402-556 1 Stop, Spring - Selector41 0828-036 2 Washer42 0831-010 2 Ring, Retaining43 0818-007 1 Shaft, Sub - Gear Shift44 1402-557 1 Gasket, Cover - Selector45 1502-009 1 Cover, Selector - Gearcase46 8405-620 6 Screw, Cap47 0830-044 1 Seal, Sub - Gear Shift48 0818-014 1 Arm, Selector49 0818-005 1 Plate, Gear Shift Cam50 0826-006 1 Screw, Cap51 0812-006 1 Plug, Drain - Magnetic52 0830-017 1 Gasket, Compression53 1402-102 1 Fitting, 90°54 0402-333 1 Plug, Fill55 0830-010 1 O-Ring56 0819-063 1 Yoke, Propeller Shaft57 1402-463 1 Joint, Universal - Set (inc. 58)58 0423-450 4 ð Ring, Retaining - Universal Joint59 0827-013 2 Nut, Hex60 0828-020 2 Washer61 0819-061 1 Yoke, Drive Output - Front Assembly62 0830-043 2 Seal, Oil - Driven Shaft63 0832-017 1 Bearing, Driven Shaft64 0828-026 1 Shim, 25.00 x 34.00 x 1.0065 1402-554 1 Shaft, Output - Secondary66 0819-002 1 Gear, Secondary Driven67 1402-555 1 Sleeve, Bearing - Output Shaft68 0832-016 1 Bearing, Driven Gear69 0819-011 1 Ring, Driven Bearing70 0819-005 1 Flange, Output Joint - Assembly71 0470-689 1 Level Stick, Lubricant72 2506-388 1 Tube, Level Stick73 0423-465 1 Grommet74 2506-445 1 Bracket - Tube75 0423-715 1 O-Ring76 0423-396 2 Screw, Self-Tapping

29


CRANKSHAFT ASSEMBLY0741-807

1 3206-019 1 Crankshaft Assembly (inc. 2-5)2 3206-020 2 ð Plug3 3206-018 1 ð Key

4 3206-022 1 ð Pin5 3206-021 1 ð Key

30


PISTON SET AND CONNECTING ROD ASSEMBLY0741-808

1 3206-026 2 Piston - Set (inc. 2-4)3206-027 2 Piston - Set (+0.50 mm)3206-028 2 Piston - Set (+1.00 mm)

2 3206-023 2 ð Ring - Set3206-024 2 ð Ring - Set (+0.50 mm)3206-025 2 ð Ring - Set (+1.00 mm)

3 3206-030 2 ð Piston Pin

4 3206-031 4 ð Circlip5 3206-035 2 Connecting Rod (inc. 6-7)6 3206-029 2 ð Bushing7 3206-036 4 ð Bolt8 3206-032 2 Bushing

3206-033 2 Bushing (-0.25 mm)3206-034 2 Bushing (-0.50 mm)

31


FLYWHEEL AND RING GEAR ASSEMBLY0741-809

1 3206-040 1 Flywheel (inc. 2)2 3206-037 1 ð Gear, Ring

3 8409-040 2 Bolt4 1402-560 1 Axle, Stub

32


DRIVE PULLEY AND ALTERNATOR BELT ASSEMBLY0741-810

1 3206-042 1 Belt2 3206-044 1 Pulley

3 3206-043 4 Screw4 3206-041 1 Screw

33


CRANKCASE, CRANKSHAFT SUPPORT, AND OIL FILTER ASSEMBLIES0741-813 *Not a Service Part

1 3206-046 1 Crankcase (inc. 2-8)2 * 1 ð Housing - Front3 * 1 ð Housing - Center4 * 1 ð Housing - Rear5 3206-054 4 ð Gasket6 3206-049 6 ð Screw7 3206-045 2 ð Sleeve8 3206-058 1 ð Pin, Tapered9 3206-053 2 Pin, Lock

10 3206-045 2 Sleeve11 3206-047 1 Plug12 3206-048 2 Plug13 3206-055 3 Bearing

3206-056 3 Bearing (-0.25 mm)3206-057 3 Bearing (-0.50 mm)

14 3206-050 2 Washer3206-051 2 Washer (+0.10 mm)3206-052 2 Washer (+0.20 mm)

15 3206-206 1 Gasket16 3206-207 1 Plug17 3206-193 1 Connector, Oil Filter18 3206-194 1 Cartridge, Oil Filter19 3206-090 1 Flange, Engine (inc. 20-21)20 3206-091 1 ð Ring21 3206-088 6 ð Screw22 3206-089 1 Gasket

34


CYLINDER HEAD AND PRECOMBUSTION CHAMBER ASSEMBLY0741-814

1 3206-063 1 Cylinder Head (inc. 2-14)2 3206-065 1 ð Plug3 3206-148 4 ð Retainer4 3206-147 4 ð Spring, Valve5 3206-149 4 ð Washer6 3206-076 1 ð O-Ring7 3206-275 ð Plug8 3206-074 1 ð Retainer9 3206-075 1 ð Washer

10 3206-077 1 ð Bolt11 3206-061 4 ð Guide, Valve

3206-062 4 ð Guide, Valve (+0.50 mm)12 3206-073 2 ð Seat, Exhaust Valve

13 3206-152 4 ð Retainer, Valve14 3206-072 2 ð Seat, Intake Valve15 3206-066 6 Screw16 3206-064 6 Washer17 3206-069 1 Gasket, Head - 1.56-1.64 (1 small hole)

3206-070 1 Gasket, Head - 1.66-1.74 (2 small holes)3206-071 1 Gasket, Head - 1.76-1.84 (3 small holes)

18 3206-068 2 Chamber, Precombustion19 3206-079 2 Spacer20 3206-067 2 Nut, Locking21 3206-078 2 Bolt22 3206-060 2 Brace, Lifting

35


ROCKER ARM COVER AND BREATHER SYSTEM ASSEMBLIES0741-815

1 3206-081 1 Cap, Oil Filler (inc. 2)2 3206-087 1 ð O-Ring3 3206-080 1 Cover, Rocker Arm4 3206-086 1 Gasket5 3206-084 1 Connection6 3206-085 1 Separator7 3206-083 2 Screw

8 3206-082 8 Screw9 3206-200 4 Clamp

10 3206-205 1 Hose, Connection11 3206-202 1 Hose, Drain12 3206-201 1 Valve, Suction13 3206-203 1 Tube, Valve14 3206-204 1 Clamp

36


FUEL SYSTEM INJECTION PUMP ASSEMBLY0741-817 *Not a Service Part

1 3206-092 1 Pipe, Delivery (inc. 2-4)2 3206-093 4 ð Screw, Fit3 3206-095 4 ð Seal, Ring4 3206-094 1 ð Seal, Delivery Pipe5 3206-098 2 Valve, Bleed6 3206-126 2 Gasket7 3206-103 2 Spacer - 2.00

3206-104 2 Spacer - 1.903206-105 2 Spacer - 1.803206-106 2 Spacer - 1.703206-107 2 Spacer - 1.603206-108 2 Spacer - 1.503206-109 2 Spacer - 1.403206-110 2 Spacer - 1.303206-111 2 Spacer - 1.203206-112 2 Spacer - 1.103206-113 2 Spacer - 1.00

8 * 1 Spring, Pressure9 3206-114 2 Drive Rod

10 3206-115 2 Spacer11 3206-125 2 O-Ring

12 3206-123 2 Nozzle13 3206-096 4 Nut14 3206-102 2 Pump, Injection - Nozzle15 3206-097 4 Stud16 3206-133 2 Tappet17 3206-122 2 O-Ring18 3206-124 2 Gasket, Copper19 3206-059 2 Arrester, Spark20 3206-116 2 Filler21 3206-099 2 Spring, Delivery Valve22 3206-117 2 Gasket, Valve23 3206-100 2 Valve, Delivery24 * 1 Plunger, Injection25 3206-118 1 O-Ring26 3206-119 2 Sleeve27 3206-120 8 Screw28 3206-101 2 Spring, Tappet29 * 1 Push Rod30 3206-121 2 Circlip31 3206-127 1 Plate, Locking

37


CAMSHAFT AND FUEL PUMP DRIVE ECCENTRIC0741-818

1 3206-129 1 Camshaft2 3206-130 1 Sleeve3 3206-131 1 Cam

4 3206-128 1 Sleeve5 3206-132 1 Screw

38


CAM PULLEYS, TIMING BELT, AND SPEED GOVERNOR ASSEMBLY0741-816

1 3206-153 1 Pulley, Cam Driven2 3206-154 1 Belt, Timing3 3206-156 1 Washer4 3206-155 1 Screw5 3206-159 1 Pulley6 3206-158 1 Stud7 3206-157 1 Washer8 3206-142 1 Nut9 3206-160 1 Pulley, Cam Drive

10 3206-209 1 Camshaft Support (inc. 11-16)11 3206-208 1 ð Ring, Seal12 3206-088 3 ð Screw13 3206-211 1 ð Bearing, Ball14 3206-210 1 ð Seal, Oil15 3206-212 1 ð Plate16 3206-166 3 ð Screw17 3206-213 1 Flyweight Assembly18 3206-214 1 Sleeve, Control (inc. 19)

19 3206-216 1 ð Sleeve20 3206-217 1 Roller, Thrust (inc. 21)21 3206-215 1 ð Washer, Thrust22 3206-218 1 Rail, Injection Pump (inc. 23-26)23 3206-220 1 ð Plate24 3206-219 1 ð Plate25 3206-221 2 ð Screw26 3206-223 2 ð Washer27 3206-222 1 Spring, Fuel - Extra28 3206-225 2 Screw29 3206-228 1 Lever, Governor - Assembly (inc. 30-33)30 3206-224 1 ð Pin, Lever31 3206-226 1 ð Seal32 3206-229 1 ð Sleeve33 3206-227 1 ð Journal34 3206-232 1 Nut35 3206-231 1 Screw36 3206-230 1 Device, Min-Max

39


ROCKER ARM, VALVES, AND OIL SWITCH ASSEMBLIES0741-819

1 3206-135 1 Arm, Rocker - Assembly (inc. 2-11)2 3206-141 2 ð Support3 3206-137 4 ð Nut4 3206-136 4 ð Screw5 3206-134 4 ð Arm, Rocker - Intake/Exhaust6 3206-140 2 ð Arm, Rocker - Injection Pump7 3206-139 2 ð Nut8 3206-138 2 ð Screw9 3206-144 1 ð Shaft, Rocker Arm

10 3206-146 2 ð Plug11 3206-145 1 ð Pin, Lock

12 3206-064 3 Washer13 3206-142 3 Nut14 3206-143 3 Stud, Bolt15 3206-313 1 O-Ring16 3206-314 1 Cover17 3206-082 3 Screw18 3206-305 1 Elbow, Pipe19 3206-304 1 Switch, Oil20 3206-150 2 Valve, Exhaust21 3206-151 2 Valve, Intake

40


EXHAUST MANIFOLD ASSEMBLY0741-821

1 3206-294 1 Manifold, Exhaust2 3206-292 4 Stud3 3206-293 6 Nut

4 3206-297 2 Stud5 3206-291 2 Gasket, Exhaust Manifold

41


THERMOSTAT, WATER INLET FLANGE, AND OIL LEVEL STICK ASSEMBLIES

0741-822

1 3206-262 1 Thermostat - Assembly (inc. 2-8)2 3206-169 2 ð Screw3 3206-259 1 ð Cover, Thermostat4 3206-260 1 ð O-Ring5 3206-261 1 ð Thermostat6 3206-263 1 ð Body, Thermostat - Assembly7 3206-206 1 ð Gasket8 3206-265 1 ð ECT Switch/Thermistor9 3206-266 2 Screw

10 3206-264 1 Gasket11 3206-268 1 Gasket

12 3206-269 1 Flange13 3206-200 2 Clamp14 0410-111 1 Hose15 3206-190 2 Clamp16 3206-199 1 Washer17 3206-197 1 Stick, Oil Level (inc. 18)18 3206-198 2 ð Seal19 3206-195 1 O-Ring20 3206-196 1 Guard, Oil Level Stick21 3206-267 2 Screw

42


OIL PUMP ASSEMBLY0741-823 *Not a Service Part

1 3206-171 1 Pump, Oil (inc. 2-10)2 3206-167 1 ð Rotors, Oil Pump3 3206-163 1 ð Plug4 3206-162 1 ð Gasket5 3206-164 1 ð Spring, Pressure Valve6 3206-165 1 ð Rod, Drive7 3206-172 1 ð O-Ring

8 * 1 ð Plate9 3206-166 3 ð Screw

10 3206-173 1 ð Gasket11 3206-168 1 Bolt12 3206-169 6 Screw13 3206-161 1 Ring, Seal14 3206-174 2 Screw

43


OIL PAN ASSEMBLY0741-824

1 3206-179 1 Pan, Oil - Assembly (inc. 2-5)2 3206-185 1 ð Pipe, Oil - Intake3 3206-183 4 ð Screw4 3206-184 1 ð Pipe, Oil - Return5 3206-180 1 ð Pan, Oil6 3206-176 1 Seal, Oil7 3206-177 1 Seal, Oil8 3206-178 2 Stud, Hollow9 3206-192 1 Washer

10 3206-191 1 Washer

11 3206-190 2 Clamp12 3206-088 20 Screw13 3206-186 1 Gasket14 3206-187 1 Gasket15 3206-188 1 Cover, Oil Pan16 3206-189 20 Screw17 3206-181 1 Gasket, Copper18 3206-182 1 Plug19 3206-175 1 Gasket

44


THROTTLE CONTROL AND LOCKED TORQUE DEVICE ASSEMBLIES0741-825

1 3206-247 3 Nail2 3206-251 1 Plate, Safety3 3206-250 1 Plate, Safety4 3206-007 2 Gasket, Copper5 3206-252 1 Bolt6 3206-249 1 Screw7 3206-248 1 Nut8 3206-236 1 Device, Locked Torque (inc. 9-10)9 3206-233 1 ð Nut

10 3206-235 1 ð Gasket11 3206-237 2 Nut

12 3206-238 2 Washer13 3206-239 1 Rod, Tie14 3206-241 1 Lever, Throttle Control15 3206-242 1 Circlip16 3206-243 1 Circlip17 3206-244 1 Pin18 3206-253 1 Washer19 3206-246 1 Seal, Oil20 3206-245 1 Nut21 3206-240 2 Bolt

45


FUEL FILTER, ELECTRO-VALVE, AND HOSES ASSEMBLY0741-826

1 3206-014 1 Hose, Fuel2 3206-010 4 Washer, Crush3 3206-002 1 Electro-Valve4 3206-003 1 Cap, Filler5 3206-004 6 Washer, Crush6 3206-006 1 Bolt, Banjo-Fitting7 3206-007 2 Gasket8 3206-008 1 Banjo-Fitting9 3206-015 1 Hose, Fuel

10 3206-001 1 Fuel Filter - Assembly (inc. 11)

11 3206-012 1 ð Fuel Filter12 3206-013 1 Hose, Fuel13 3206-011 1 Bolt, Banjo-Fitting14 3206-005 1 Bolt, Banjo-Fitting w/Valve15 3206-009 2 Bolt, Banjo-Fitting16 8432-802 2 Nut, Lock17 8408-825 2 Screw, Cap18 0423-689 1 Clamp, Hose19 0423-688 1 Clamp, Hose

46


FUEL FEED PUMP AND PUSH ROD ASSEMBLIES0741-841

1 3206-009 2 Bolt, Banjo-Fitting2 3206-010 4 Washer, Crush3 3206-245 2 Nut4 3206-234 2 Washer5 3206-254 2 Stud

6 3206-255 1 Pump7 3206-257 1 Rod, Push8 3206-256 1 O-Ring9 3206-258 1 Banjo-Fitting

47


WATER PUMP ASSEMBLY0741-827

1 3206-271 1 Pump, Water - Assembly2 3206-273 2 Screw

3 3206-274 2 Screw4 3206-272 1 Gasket

48


INTAKE MANIFOLD AND THROTTLE CONTROL ASSEMBLY0741-832

1 3206-276 3 Screw2 3206-278 1 Manifold, Intake3 3206-277 1 Gasket, Intake Manifold4 3206-286 1 Lever, Internal5 3206-283 1 Spring, Recovery6 3206-284 1 Sleeve7 3206-285 1 Screw8 3206-280 1 Screw9 3206-279 1 Screw

10 3206-288 1 Pin

11 3206-287 1 Lever, External12 3206-242 1 Circlip13 3206-281 1 O-Ring14 3206-290 1 Flange, Intake15 3206-289 1 Gasket16 3206-169 2 Screw17 3206-234 2 Washer18 3206-266 4 Screw19 3206-137 1 Nut20 3206-282 1 Bolt

49


EXTERNAL ALTERNATOR ASSEMBLY0741-833

1 3206-303 1 Alternator2 3206-300 1 Support, Alternator3 3206-142 1 Nut4 3206-298 1 Washer5 3206-301 1 Bolt6 3206-302 1 Washer

7 3206-266 3 Screw8 3206-298 1 Washer9 3206-299 1 Bolt

10 3206-324 1 Wire w/Diode11 3206-325 1 Clamp12 3206-137 1 Nut

50


STARTER MOTOR ASSEMBLY0741-838R

1 3206-319 1 Motor, Starter2 3206-322 1 Washer, Lock3 3206-321 1 Nut

4 8409-030 1 Flange Head5 1402-525 1 Gasket

51


BELT GUARD ASSEMBLY0741-840

1 3206-315 1 Guard, Belt2 3206-043 3 Screw3 3206-189 1 Screw

4 3206-318 1 Cap5 3206-317 1 Gasket6 3206-316 1 Plug

52


CONTROL SWITCH HOUSING ASSEMBLY0738-416

1 0409-083 1 Switch, Control - Assembly (inc. 2-3)2 3423-196 1 ð Screw3 0409-028 1 ð Screw4 3409-019 1 Cover, Housing5 AC003-192 1 Switch ON/OFF Orange MF6 AC003-014 1 Control Light Blue7 AC003-270 1 Combi-Switch8 AC003-053 11 Blade-Terminal Insulated 9 AC003-031 2 Connector

10 AC003-033 2 Terminal Locks

11 AC003-034 2 Cavity Plugs12 AC003-032 4 Crimp Terminals13 0409-103 2 Connector14 0409-104 4 Terminal15 0409-105 4 Seal16 AC003-019 2 Deutsch Stiftstecker (M)17 AC008-428 2 Bushing Connector18 AC008-435 2 Male Connector19 AC003-266 2 Male Connector PROWLER20 AC003-267 2 Push On Contact Grommet PROWLER

5

6

8

9

10 11

12

14

15

16

17 18 19

20

7

13

53


THROTTLE CASE ASSEMBLY0738-414

1 0509-012 1 Case, Throttle - Assembly (inc. 2-9)2 3409-001 1 ð Lever3 3004-533 1 ð Screw, Cap4 3004-447 1 ð Washer, Lock5 3003-030 1 ð Washer

6 3423-014 1 ð Screw7 3423-327 1 ð Nut8 3423-199 2 ð Screw9 0409-048 1 ð Cover, Throttle Case w/Switch

54


TOP END GASKET SET ASSEMBLY(Top End Gasket Set p/n 3206-328)

0742-255

1 3206-152 4 Retainer, Valve - Cylinder Head2 3206-086 1 Gasket, Rocker Arm Cover3 3206-084 1 Connection, Rocker Arm Cover4 3206-095 4 Seal, Ring - Delivery Pipe5 3206-094 1 Seal, Delivery Pipe6 3206-122 2 O-Ring, Injection Nozzle7 3206-124 2 Gasket, Copper - Injection Nozzle8 3206-059 2 Arrester, Spark - Injection Nozzle9 3206-208 1 Ring, Seal - Governor Cover

10 3206-210 1 Seal, Oil - Governor Cover

11 3206-226 1 Seal, Governor Lever12 3206-313 1 O-Ring, Cylinder Head Flange13 3206-291 2 Gasket, Exhaust Manifold14 3206-296 1 Gasket, Exhaust15 3206-260 1 O-Ring, Thermostat16 3206-010 4 Washer, Crush17 3206-256 1 O-Ring, Fuel Feed Pump18 3206-277 1 Gasket, Intake Manifold19 3206-289 1 Gasket, Intake Flange

55


BOTTOM END GASKET SET ASSEMBLY(Bottom End Gasket Set p/n 3206-329)

0742-254

1 3206-054 4 Gasket, Crankcase2 3206-091 1 Ring, Engine Flange3 3206-089 1 Gasket, Engine Flange4 3206-264 1 Gasket, Thermostat5 3206-172 1 O-Ring, Oil Pump

6 3206-173 1 Gasket, Oil Pump7 3206-161 1 Ring, Seal - Oil Pump8 3206-176 1 Seal, Oil - Oil Pan9 3206-177 1 Seal, Oil - Oil Pan

10 3206-272 1 Gasket, Water Pump

56

0436-925 Bag, Rack, Front, Black0436-480 Bar, Utility0436-619 Brush Guard/Bumper - Deluxe0436-794 Bumper - Rear0436-827 Cargo Box0436-460 Carryall (11 x 17)0436-462 Carryall (10 D)0436-726 Cover, Trailerable0436-087 Electrical Plug0436-466 Fender Box0436-538 Gear Cradle0436-905 Grease, High-Performance0436-828 Gun Holder0436-352 Hand/Thumb Warmers0436-463 Light Bar0436-774 Lunch Pack, Black2257-970 Manual, Illustrated Parts 2257-907 Manual, Operator’s (E)2257-920 Manuel d’utilisation (F)0652-024 Paint, Metal - Black

0436-635 Plow Attachment Kit0436-228 Plow Blade, 50 in. - Straight0436-287 Plow Blade, 50 in. - One-Way0436-296 Plow Blade, 60 in. - Straight0436-360 Plow Blade, 60 in. - One-Way0436-636 Plow, Push Frame0436-626 Rack Basket0436-965 Saddlebag

(with passenger seat attached)1436-028 Seat, Passenger0436-026 Tire Chains, Size B

(24 in. and 25 in. Tires)0436-027 Tire Chains, Size C

(25 in. and 26 in. Tires)1402-028 Tire, Titan AT589

(25x8-12, Mud & Snow)0402-563 Tire, Titan AT589

(25x10-12, Mud & Snow)0436-656 Winch Accessories Kit0436-979 Windshield, Black

RELATED ITEMS2007 ATV 700 Diesel

Red Green

NOTE: For a complete list of related items, refer to the current accessory catalog.

Printed in U.S.A.

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